Integrated automation system

ABSTRACT

A method and apparatus for communication for a supervisory control and data acquisition (SCADA) system, the SCADA system comprising: an enterprise server; at least one intelligent electronic device (RTU), wherein the RTU measures a physical process and stores digital data representative of the measurement in a memory area for transmission; a configuration tool (AES) linking the SCADA server with the RTU; a connection device (TAC) for installing the SCADA system on related software program; a gel encapsulation layer (GEL), the method comprising the steps of: (1) communicating a command from the enterprise server to said RTU via the AES to configure said RTU; (2) permitting said RTU to receive data input and to store said data; and (3) transmitting said data back from the RTU to the enterprise server.

FIELD OF THE INVENTION

[0001] The present invention relates to an integrated automation systemthat has utility in the refining, petrochemical and chemical processingindustries as well as the oil and gas production industry, metalmanufacturing industry, maritime drilling businesses and enviromnentalmonitoring. In addition, the present invention relates to a system foruse with electrical production and distribution, waste treatment anddistribution, wastewater treatment and gas pipelines and distribution.

[0002] The invention relates to Supervisory Control and Data Acquisition(SCADA) systems generally. In addition, the invention relates to methodand apparatus for use in the communication for a SCADA system includinguse of Intelligent Electronic Devices, which are also called remoteterminal units in this application or “(RTU)”

BACKGROUND OF THE INVENTION

[0003] The automation industry has had major developments in theimplementation of SCADA monitoring and control systems. A need has longexisted for an integrated system, which uses small PC's to run factorylines, and other large manufacturing facilities.

[0004] The integration problems were rampant in the industry. Either,hosts were inadequate or defective. A unique RTU was developed tofacilitate the integration of software.

[0005] 1. A need has long exists for a less expensive RTU

[0006] 2. A new board has been desired to reduce the costs of RTU by atleast 25%

[0007] 3. A need has existed for a system, which works faster thantraditional host systems

[0008] 4. A need has existed for an improved SCADA system and method ofcommunication, which can talk to more systems as host more thantraditional systems.

[0009] A vital part of any process control system is the initialcommunication and periodic point-to-point communication of the system,including the process input values, the database, the displays and thelike. Such a communication procedure is associated with a SCADA system,which in its most generic definition is essentially a process controlsystem. The components of a typical SCADA system comprise a SCADA deviceand one or more remotely connected Intelligent Electronic Devices. Asused herein, the term SCADA device is used as a convenient shorthand forwhat may be a collection of electronic equipment, including a computerbased controller, which can be a server, also termed the “enterpriseserver” that is used to remotely monitor communication and/or controlthe operation of one or more remote RTUs such as relays, meters,transducers and the like. In general, the enterprise server is locatedmiles away from the RTUs presenting many SCADA system communicationdifficulties. However, such a definition should not preclude anenterprise server being located much closer, even in the same plant asthe RTU or RTUs.

[0010] Communication for a SCADA system traditionally has been very timeand labor intensive. The initial set up of the RTU required an expensivetechnician to go into the field to configure the RTU. Subsequentmaintenance communication has also been particularly time and laborintensive where the RTU is in an extremely remote location, such as on amountain top or under snow on a pipeline in Alaska with respect to theenterprise server. In such a case, transportation and communicationproblems have been abundant. Therefore, reducing the time and effortrequired to run communication of a SCADA system while insuring that theSCADA device database and overall SCADA system operation meets thehighest possible accuracy standards would provide substantial costadvantages over current communication procedures.

[0011] Traditionally, RTU configuration has involved steps of:

[0012] 1. Assembling and transporting to the RTU location a collectionof complex and expensive test equipment and signal generators that arerequired to produce the needed configuration

[0013] 2. Requiring an expensive technician at the remote location toinject the data into the RTU's inputs.

[0014] 3. Requiring a second expensive technician at the centrallocation(s) to verify the RTU is correctly processing according to thenew configuration.

[0015] 4. Such a system presents many drawbacks. For example, twotechnicians at disparate locations are required to perform the service.One of the technicians may be required to travel long distances.Moreover, in most SCADA systems, the RTU must be disconnected from theprocess that it is monitoring and/or controlling, which may affect theprocess under control.

[0016] 5. There is a need for method and apparatus that address theshortcomings of present communication of a SCADA system. These needs arenow met by the present invention.

BRIEF DESCRIPTION OF THE FIGURES

[0017] The following detailed description of the preferred embodiment,is better understood when read in conjunction with the appendeddrawings. For the purpose of illustrating the invention, there is shownin the drawings an embodiment that is presently preferred, it beingunderstood, however, that the invention is not limited to the specificmethods and instrumentalities disclosed.

[0018]FIG. 1 is a SCADA system according to the present invention.

[0019]FIG. 2 provides a detail of an RTU of the present invention.

[0020]FIG. 3 is a detail of a user interface with a enterprise.

[0021]FIG. 4 a diagram of international with external systems.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] According to a presently preferred embodiment, a system andmethod for communication in a SCADA system will now be described withreference to the Figures. It will be appreciated by those of ordinaryskill in the art that the description given herein with respect to thoseFigures is for exemplary purposes only and is not intended in any way tolimit the scope of the invention. For example, an RTU is describedherein with reference to a remote terminal unit, such as amicroprocessor-based meter is merely for the purpose of clearlydescribing the present invention and in not intended as a limitation.The RTU could be, for example, a microprocessor-based meter. The methodsdescribed herein could be provided as a software package that operatesdirectly on the RTU or on the SCADA device.

[0023] Referring now to FIG. 1, there is shown a SCADA system 10 of thepresent invention. As shown, the system comprises an enterprise server12, which has a display device 14 for displaying data to a humanoperator (not shown). A second enterprise server 16 can optionally beconnected to the system, which may have a display device 18 connectedthereto. An RTU 20 such as a microprocessor-based relay, which monitorsand/or controls a physical process 22, and an optional local computer 24for configuring RTU 20 locally.

[0024] RTU 20 communicates with enterprise servers 12 and 16, via aconnection called TAC 26. TAC 26 can reside on server 12 or betweenserver 12 and server 16, or on local computer 24..

[0025] Software termed the “AES” 28 is the configuration tool which cancommunicate with the RTUs. Configuring occures by use of a configurationtool, ARME. The AES can reside on the server 12, 16, or between 12 and16 or on the local computer 24.

[0026] Generally, in this system, the RTU measure physical propertiesand can be remotely configured by the AES 28. Additionally, the RTU'scan run simulations, and provide that data to the enterprise server 12or 14 based on instruction via the AES.

[0027] For a simulation, a, SCADA system 10 requires communication withRTU 20 and the enterprise server 16 and/or 14, or even others.

[0028] The AES provides by RTU 20 with simulation instructions so theRTU can run tests without the need for an operator or expensive testequipment to inject a new configuration of an RTU into system 10.Moreover, RTU 20 can continue to monitor and/or control process 12,while the simulation is running.

[0029] Referring to FIG. 2, an exemplary RTU 20 is shown in furtherdetail. As shown, the essential parts of RTU 20 comprise amicroprocessor 30, an analog-to-digital converter (ADC) 32, a digitalsignal processor 34, a communication interface 36, such as at least onebidirectional port or one or more directional input ports or interfaces,or output ports or interfaces 38, a user interface 40 and a memory area42. Memory area 42 comprises both Read-Only Memory (ROM) and RandomAccess Memory (RAM) and comprises both a program memory 44 and acommunication port register memory 46, which includes a commandregister.

[0030] As with many standard RTUs such as the microprocessor-basedrelay, RTU 20 measures aspects of a physical process 22 such as currentsand voltages and converts the measured values into a digital equivalentvia ADC 32 and digital signal processor 34. Microprocessor 30 moves thedigital representation of the measured values into memory area 42 wherethe data can be accessed by programs and external devices such as anenterprise server. Moreover, microprocessor 30 can perform variouspredetermined functions on the data, such as fault detection as in thecase of a relay, or control the process. Microprocessor 30 is also incommunication with communication interface 36, also known as the AES sothat data (i.e., digital representative data) can be transferred to anexternal device such as enterprise server 14 or 16 or both, or even moreservers.

[0031] Additionally, communication interface 36 (the AES) allows anexternal device such as local computer 24 or enterprise server toprovide commands and data to RTU 20.

[0032] Input/output interface 38 is coupled to microprocessor 30 andprovides binary input signals from a controlling device. Moreover, RTU20 provides control signals to the controlling device such as a breakerclose or open signal if the controlling device is a circuit breaker.

[0033] User interface 40 provides a local mechanism for gaining accessto the data in memory 42. In this way, a local operator can provideinitial configuration data to RTU 20 or check the status of data withinmemory 42.

[0034]FIG. 3 shows the detail of the reconfiguration process. Forreconfiguration while an RTU is on line, a user interface 46 providesinput parameters to the RTU via an input device such as a keyboard or akeypad at the server 12. Additionally, interface 46 may displaycommunication data from the RTU allow a user to change the values forthe data stored in the RTU. Alternatively, this same user interface 46,can initiate steps to place RTU 20 is in a simulation or test mode.

[0035] Significantly, user interface 46 provides another mechanism tocommand RTU 20 and place RTU 20 either “off line” or into a “sleepmode”. Specifically, user interface 46 can be used to remove specifictasks by interval or entirely from the task list initially installed inthe RTU. This same interface permits additional tasks to be added to theRTU. If a task is deleted from the RTU, or if the RTU is put intoperiodic “wake up” mode, the RTU will not store data in memory, ortransmit. This feature is particularly useful for a system to be used onlong space flights, where the Houston Johnson Space Center needs to only“wake up” certain RTU's at periodic times.

[0036] Additionally, user interface 46, which interacts with the AESprogram 28 permits a user to request internal diagnostics from the RTUto determines the internal status of RTU 20 such as memory failure orprocessor failure while all other RTU and servers remain on line.

[0037] Referring now to FIG. 4, a flow chart is shown that depicts theinteraction of an RTU for metering electricity with a SCADA system ofthe invention.. During normal operation, a metering module 46 writesmetered values to register memory 42. Moreover, input/output task 48writes binary status values to register memory 42. The register memoryvalues written by metering module 46 and input/output task 48 are, thentransmitted to the enterprise server 14 for further processing. Asdescribed in above, communication port with communicates with the AEScontrols the interaction between RTU 20 and enterprise server 14. Forclarity and brevity, the communication process is described in referenceto communication interface 36.

[0038] During a typical communication sequence (i.e., normal mode) threesteps are performed. First, a command is received via communicationinterface 36 requesting the transmission of data values from memory 42.The data values are then retrieved from memory 42, and prepared fortransmission via the AES, for example, properly formatting the data.Finally, the prepared response is transferred to the external is devicevia the AES. An encapsulation layer (GEL) is also used.

[0039] The following terms are used here in.

[0040] 1. The term “SCADA” means Supervisory Control and DataAcquisition Systems.

[0041] 2. The term “ARME” means the RTU configuration or maintenancetool for the SCADA system. ARME is an OPC Client that communicatesthrough the AES that allows RTU's to be remotely reconfigured afterdeployment. TAC combines with AES to provide a data acquisitionfront-end for relational databases.

[0042] 3. The term “TAC” means The AutoSol Connection, which is a dataacquisition front end connection for databases.

[0043] 4. The term “GEL” means Generic Encapsulation Layer.

[0044] The invention relates to communication technology which cansimultaneously handle multiple types of telemetry and differentprotocols from various remote terminal units, such as custody controlcomputers for pipes lines, pump off controllers, nonspecificcontrollers, and water meters.

[0045] The invention is a server-based system that can provideinformation to a wide variety of client server interfaces, with the onlylimitation on capacity being bandwidth and processing power.

[0046] The invention works with lease line, radio, public switchedtelephone networks, cellular phones, and satellite and Internettelemetry reception.

[0047] For example, this invention could handle the communication forutility metering for an entire city. Multiple servers of the inventioncan be used, and the servers can be used in parallel to each other, andenable millions of terminals to receive and transmit communications to acentral server and enables the utility to configure millions of RTU's atonce.

[0048] The invention involves several features, an AES communicationtool which has as the new benefits, the ability to conserve resourceswithin an operating system including, memory, and the number of threads,which can be run through Microsoft NT. This new SCADA system wasdeveloped to handle these and other objects, including an ability of theuser to assign threads to specific ports to conserve thread.

[0049] The AES communication system is capable of handling communicationsystems with over 100,000 RTU's while continuing non-stop communicationwith no downtime. The AES component enables the user to add or deleteRTU while continuing to operate and function on line. This AES componentalso enables the user to add additional servers to the AES while theuser is on line, without downtime.

[0050] The AES, is essentially a windows-based OPC server, (objectlinking and embedding for process control), which communicates with aplurality of RTU's simultaneously. The present invention relates to awindow based communication server that permits digital communication toa field device, and enables the user to digitally connect or disconnectany one or more of the RTU while the system is operating on line. Therecould be at least 1000 RTU's engageable and disengageable while thesystem is on line. The system includes hardened computers suitable forperforming remote automation in environmentally exposed locations usingsoftware compatible with the Windows 98, NT and 2000 operating systems.

[0051] The hardware of the invention is capable of performing remotecontrol, alarm detection, data acquisition, and data managementfunctions. The software provides communication to RTU's via telemetrysystems, acquired data management via commercially available databases,such as Oracle, Microsoft Access, Microsoft SQL server, and Cybase andRTU status and performance values and parameters to data centers.

[0052] The AES preferably runs as an NT server. AES has:

[0053] 1. Connection modules, which are connected from a standard port,and include:

[0054] a. TCPIP

[0055] b. Dialup

[0056] c. Serial

[0057] Other modules could be added depending on the hardware interface,such as an ARC NET connection module; and

[0058] 2. Protocol Modules—the messaging language

[0059] a. Enron Modbus protocol module

[0060] b. ABB total flow module

[0061] SCADA system hardware usable in this invention includes at leastone such as the RTU 3000, 4000E or 5000E. These models have differentI/O capability, with the 3000 unit being the smallest and onlycommunication ports to meet different application requirements andbudgets.

[0062] The inventive SCADA system includes:

[0063] 1. ARME;

[0064] 2. AES,

[0065] a. Communication Software that is an NT Service

[0066] b. Configuration Software which is an ActiveX Control, and

[0067]3. TAC.

[0068] The ARME is the RTU configuration or maintenance tool for theSCADA system. ARME is an OPC Client that communicates through the AESthat allows RTU's to be remotely reconfigured after deployment. TACcombines with AES to provide a data acquisition front-end for relationaldatabases.

[0069] TAC not only is an OPC Client but also has an ODBC interface thatis compatible with all leading relational database products.

[0070] The ActiveX AES Configuration Software merges with any othersoftware that is an Active X container to allow modification of the AESCommiunication Software. The AES Configuration Software has specificfeatures that allow the remote configuration of the AES CommunicationSofware, such as over the Internet. The AES Configuration Softwareprovides a set of windows that allows the end user to define thecommunication desired with the RTU. For example, if a client wants tocommunicate with a “Totalflow” instrument, a window allows the user toset up the connection type, and then set up a virtual port associatedwith that connection type. A Windows Interface allows the user to selecta serial connection type or serial port, and define multiple virtualports, which are associated with an actual port, such as a COM Port 1.Next, the user selects a protocol, such as Modbus. The user then definesa device, which is to be communicated with via the Modbus protocol. Allcommunication parameters are then selected and then the AESCommunication Software is setup for communication with the devicethrough the port.

[0071] The AES Configuration Software can modify an offline databasewhere the interface is OLE DB. This feature allows the invention to becompatible with any relational database. When a new device is selected,or new parameters are entered, the changes that are made to the offlinedatabase are automatically assimilated by the AES CommunicationSoftware.

[0072] AES and ARME and TAC run on Microsoft Windows 98TM, NTTM, or2000TM. The host system (personal computer) requires a minimum of 66 MHzprocessor speed and a minimum of 16 Megabytes of RAM. The preferredsystem would be a 500 MHz process with at least 125 K of Ram.

[0073] The host system's operating environment must be Microsoft Windows98TM, NTTM, or 2000TM, with 2000TM being the preferred operating system.The invention is compatible with Win32API. The modular design, based onCOM Objects, a Microsoft standard, allows the present invention to beextended to support different connection types and protocols.

[0074] Communication can be established between a Microsoft Windows basecomputer and an RTU immediately upon powering the RTU and without RTUconfiguring or programming.

[0075] Automation functionality in the RTU can setup through thefollowing method:

[0076] 1. Step 1: Select a automation function to be executed in the RTUfrom the functions available in an ARME program.

[0077] 2. Step 2. Select additional parameters associated with thespecific function.

[0078] 3. Step 3: Communicate the function from ARME through the AES tothe RTU;

[0079] 4. Step 4: Optionally functions can be added to a function mapand portions or all of the function map can be communicated from ARMEthrough the AES to the RTU;

[0080] 5. Step 5: Optionally functions can be added to a function mapand communicated from ARME through AES simultaneously to many RTU's;

[0081] 6. Step 6: Reconfigures existing RTU's via the AES with newfunction maps simultaneously.

[0082] 7. Exemplary function blocks that solve data processingapplication problems include:

[0083] a. Staging function block,

[0084] b. Analog alarm function block,

[0085] c. Gas metering calculation block,

[0086] d. Digital alarm blocks,

[0087] e. Archive blocks containing historical measurement or datarecords with date stamps

[0088] f. The ARME consists of function maps.

[0089] At least one library of function blocks that can be included ineach map. The ARME has customizable function block ability; enabling endusers to self develop and customize function blocks with a VB language.The ARME overwrites a Simulation Environment to simulate a function mapin a host computer prior to loading the function map in an RTU. The ARMEcan download function maps to RTU; upload function maps from RTU's; andsynchronize to one or more RTU's with the internal computer clock.

[0090] The RTU has a software component termed “the soft RTU” which isloaded on the hardware, the “RTU hardware.” The soft RTU has a specialoperating system, which executes on the function maps, which aredownloaded to the RTU.

[0091] The hardware interface layer is called the Generic EncapsulationLayer or GEL. This hardware interface contains all the low-levelcommunication programs, which enable the soft RTU to communicate withthe Enterprise server. Some of these programs include, timing programs,communication buffers, I/O scanners, memory management, real time clock,power management routines.

[0092] To operate the soft RTU, controls in individual function blocksindicate to the operating system of the soft RTU when they shouldexecute. The default configuration of the soft RTU enables immediatecommunication of the RTU with SCADA system at the moment of power up.Access to all I/O points on the RTU is also granted at the moment ofpower up.

[0093] RTU 4000 of the present invention is designed so that allhardware features can be configures from ARME. This means the user nolonger has to have dipswitches, plug in modules, or jumpers. This savestime so that all hardware options with regard to I/O and communicationare set in software only. There is only one reason to open the box ofthe RTU of the invention that is to activate the lithium battery, whichis good for at least 10 years.

[0094] Features of the novel RTU include the ability of the RTU to putitself to sleep, based on change of status. It can be set to wake upperiodically, or be woken up by telephone. It can be put to sleepperiodically as well.

[0095] The invention contemplates using 8 analog inputs, which can becurrent, or voltage inputs and the input that are desired, can be pickedby the software of the soft RTU.

[0096] A multifunction I/O point can be set up as (a) a digital input, adigital output, initializing off, initializing on, a low speed counterand a low speed counter of 0-10 kilohertz, a high speed counter of 125Kilohertz to 400 kilohertz, a pulse output, a quadracure decoder.

[0097] It should be noted that Corn Port 1 is always, 232, Corn Port 2and 3, can be RS 232 or RS 235 and be software configurable.

[0098] Very little power is required by the RTU when it is asleep. Itcan be powered for 10 years on the one battery.

[0099] In a preferred embodiment, a 12 VDC power supply can power theRTU 4000E. While terminating power supply wires to the RTU be sure tothe power supply is off. A 12 VDC power supply or battery can beconnected to the (+) 12 VDC terminal and the (−) 12 VDC (The powersupply common should be terminated here. After connecting the powersupply wires to the RTU, Turn-On the supply. Power-up should beindicated by the 12 VDC pilot light, which can be used as an indicatorto check power connections.

[0100] Once the RTU is powered the next step is to establishcommunications between the RTU and preferably an Intel computer equippedwith Windows 95TM or Windows NTTM. The RTU initially, permits directwiring of the RTU, however, just after power up with RTU may beconfigured to communicate via radio, lease line, internet or publictelephone, however the following procedure will enable a user to use adefault configuration to connect.

[0101] For direct communication a standard Null Modem cable should beconnected to one of the three RTU 4000EE serial ports (DB9 Male serialconnectors) and to COM2, the second serial port on the Intel computer.If COM2 is not available, other COM Ports may be used. To use other COMPorts, attach the serial cable to the desired COM Port's; ConfiguringPorts.

[0102] The AES is compatible with Window 95TM or Windows NTTM. AESsupports communication with various RTU's and other vendor productsthrough a computer serial port or network card. Other software packagescan communicate with the RTU through AES and its DDE (Dynamic DataExchange) or OPC (OLE for Process Control) Server interface.

[0103] AES is installed by running an SETUP.EXE program as follows:

[0104] 1. Start Windows 95TM, Windows NTTM

[0105] 2. Insert the distribution diskette into a floppy drive

[0106] 3. From the Windows Program Manager, invoke the File/Run&#8230;command.

[0107] 4. Enter A:\SETUP (or B:\SETUP.EXE if the diskette is in drive B)and click on the OK or press <ENTER> key. The Setup dialog box willappear:

[0108] The RTU 4000E1 is a hardened industrial controller suitable forinstallation in environmentally exposed locations. The RTU's 32-bitMotorola 68332 processor, 256 Kbytes of battery backed Static RAM and 16Mbytes of Flash RAM provide strong computing power to perform complexcontrol and data management activities. The RTU 4000E1 has three serialports that can be used for communication with host computers, pagers,subordinate RTU's, I/O, analyzers and/or other vendor PLC's and RTU'S.Lastly, the RTU 4000E1 has 53 I/O points that can be interfaced toinstruments and actuators to measure and effect changes to process orequipment status'; and conditions.

[0109] When power is initially applRTU to an RTU 4000E1 the FactoryDefault; configuration retained in the RTU's flash memory is loaded tostatic RAM where it is executed. (The active configuration in static RAMis the On-line configuration.) This configuration allows immediateaccess to the RTU's I/O through the serial ports and the Modbus protocolon power-up. To setup the unit for an automation purpose the user candevelop a configuration from a library of Function Blocks embedded inthe RTU 4000E1 with the ARME configuration tool. Once loaded, this newconfiguration replaces the Factory Default and is called the UserDefault configuration.

[0110] The RTU 4000E1 is preferably packaged with a metal mounting plateand cover. This packaging provides RFI protection but does not provideenvironmental protection from moisture, dust, corrosive chemicals andatmospheres. In addition, the RTU is not suitable for installation inindustrial areas that have a hazardous classification. Additionalpackaging however, can often meet these requirements.

[0111] The RTU 4000E1 has Power Input terminations and Battery Inputterminations as shown in FIG. 3. These power inputs are OR'ed in the RTUpower circuitry such that if one source is removed, the RTU will drawfrom the remaining power source. The Power Input terminations are theprimary power source and can accept from 11 to 30 VDC. The Battery Inputterminations are intended for a system back-up battery and will acceptfrom 9 to 14 VDC. Circuits associated with the Battery Input will alsotrickle charge the back-up battery as long as 11 to 30 VDC is applRTU tothe Power Input terminations. Should the Power Input voltage fall below11 VDC the RTU will automatically draw from the Battery Input powersource. When the Power Input voltage returns to a level between 11 and30 VDC the RTU again draw power from the Power Input terminations andtrickle charge the backup battery. When input voltages fall below 9 VDC,a low voltage cutout will protect the RTU from indeterminate states thatcan occur.

[0112] LED indication of the status of power at the Power Inputterminations and the Battery Input terminations are provided on the faceof the RTU above the Reset button. When power is applRTU to either thePower Input or the Battery Input terminations the LED will be visible.When power is only applRTU to the Battery Input the LED will also bevisible.

[0113] RTU 4000E1 has two grounds, which serve different purposes andmust not be connected during the installation process. Transients, radiofrequency interference (RFI) and over-voltage protection circuitry inthe RTU are designed to transfer these disruptive or destructive signalsto earth ground. The protection circuits connect to the mounting platethrough mounting pads on the RTU circuit board. The installer shouldtake care to insure that the mounting plate is also connected to areliable earth ground. In addition the installer should collect all ofthe shields associated with instrument cables/wiring to RTU I/O at theRTU end and should connect these shields to earth ground.

[0114] The digital grounds associated with Digital I/O, MultifunctionI/O and Analog I/O is connected within the RTU to Power Input andBattery Input grounds. As indicated in the Power and Battery Backupsection above these grounds should be connected to the Common terminalof the power supply and/or to the Negative Terminal of the Back-upBattery.

[0115] An internal lithium back-up battery is provided in the RTU 4000E1to maintain static RAM and the Real Time Clock when power is removedfrom the Power Input and Battery Input terminals. Current controlset-points or targets, accumulated values and alarm thresholds that arebeing executed in static RAM may be different from those of the initialconfiguration maintained in flash RAM. The lithium battery, with anominal life of 10 years, will maintain all of these settings in staticRAM. It is necessary however, to install a jumper on the RTU circuitboard to activate the internal back-up battery. To install, remove theRTU cover and locate the jumper next to the lithium battery in the upperright hand corner of the RTU circuit board. Press the jumper on the twopens and replace the RTU cover.

[0116] The user can control power consumption in the RTU to a largeextent. Under normal operating modes the RTU nominally draws 115 mA at14 VDC from the Power Input source. This does not include the additionalpower draws of instrumentation, telemetry hardware or other devices thatmay be included in an RTU installation. The user can reduce this powerconsumption by putting the RTU in a sleep mode on an interval or on anevent. This capability can be configured through the ARME. In the SleepMode the RTU draws 13 mA at 14 VDC from the Power Input Source. Finally,further reductions can be made by selectively or completely deactivatingLED indications on the face of the RTU. Again this feature is configuredthrough ARME.

[0117] The RTU's are designed to monitor and control assets inenvironmentally exposed installations and to receive supervisionregarding that mission from a remotely located data center. As a result,flexible communication to data center computers is a key capability. TheRTU 4000E1 has three serial ports that can be individually configuredfor Master or Slave communications, different Modbus Slave IDs,communication parameters, hardware handshaking, password protection,privileges, and telemetry methods.

[0118] On initial power-up RTU 4000E1 I/O is accessible through any ofthe three serial communication ports and the Factory Default serial portvalues. The default settings for the serial ports are given in Table 1below.

[0119] The RTU I/O is also accessible through the Modbus addressingprovided in Table 2 below. Note that the address of some points isdependent on the configuration. The address for the defaultconfiguration of a particular I/O point is indicated in bold. Asindicated in Table 2, all of the I/O in the RTU 4000E1 have pre-assignedModbus addresses with the exception of the two analog outputs for whomholding addresses are assigned by ARME.

[0120] In addition to the default configuration detailed in Table 1, RTU4000E1 serial ports default to the RS-232 electrical standard. COM Ports2 and 3 however, can be configured by ARME to support RS-485. FIG. 4shows the locations of the COM Ports and associated LED's. LED's areprovided to indicate the status of serial communication lines. Inaddition, the indicators located to the left of the Port 2 and 3 LED's;indicate whether these ports are configured for RS-232 or RS-485. TheRTU 4000E1, which is a DTE device, is connected to computers and modemsthrough standard serial cables. When connecting to computer serial portsa Null Modem cable should be used. When connecting to a modem or a radiomodem a Straight-through cable should be used. Additionally, whencommunicating through modems that require hardware handshaking the cablewill require the RTS, CTS and DCD lines in addition to TX, RX and GND.

[0121] In the preferred embodiment, the CPU is a Motorola 68332 16 MHzhaving 512 KB Static RAM and 4 MB Flash RAM.

[0122] The preferred temperature range for operation of the SCADA systemis −40 deg C. to 85 deg C.

[0123] The Analog Inputs Software are Selectable 0 to 5 VDC or 4 to 20ma

[0124] The Analog Output Software Selectable 0 to 5 VDC or 4 to 20 ma.

[0125] The Multifunction I/O's can be configured in the software as:

[0126] 1. Digital Inputs (DI),

[0127] 2. Digital Outputs (DO),

[0128] 3. Low Speed Counters/Accumulator (LSC),

[0129] 4. High Speed Counters (HSC),

[0130] 5. Pulse Outputs (PO),

[0131] 6. Quadrature Decoder (QD), or

[0132] 7. Pulse Width Modulation (PWM).

[0133] 8. DI Mode—5/12/24 VDC Sink

[0134] 9. DO Mode—5/12/24 VDC Sink

[0135] 10. HSC Mode—125 Hz to 100 KHz @ 5 DC to 36 VDC

[0136] 11. LSCMode-0 Hz to 10 kHz@5 VDC to 36 VDC

[0137] 12. PO Mode 125 Hz to 100 kHz@ 5 VDC

[0138] 13. PWM Mode 125 Hz to 100 kHz Duty Cycle

[0139] Add-on modules can convert any of these 11 points to additionalAnalog Inputs, Thermocouples Inputs, RTD Inputs, or Analog Outputs.

[0140] There are 32 Digital Points in the software and include:

[0141] 1. Digital Inputs (DI) 5/12/24 VDC Sink

[0142] 2. Digital Outputs (DO) 5/12/24 VDC Sink

[0143] 3. LED indication for all Digital Points

[0144] 4. Transient Protection

[0145] 5. Compliant with IEEE 472 and ANSI 37.90.

[0146] The Serial Communication Ports are preferably:

[0147] 1. Port 1 EIA-232, full handshaking, DB-9 Male.

[0148] 2. Port 2 EIA-232/485, software selectable, full handshaking,DB-9 Male.

[0149] 3. Port 3 EIA-232/485, software selectable, full handshaking,DB-9 Male.

[0150] 4. LED indication of Port 2/3 EIA-485 mode.

[0151] 5. LED indication of DTR, TX, RX, DCD, RTS, and CTS for eachport.

[0152] The Power Supply is preferably set with:

[0153] 1. Three power modes: Un-powered, Sleep, Operational

[0154] 2. Primary Power Input

[0155] 3. Power Requirement 11-30 VDC

[0156] 4. Operational Mode: Minimum power draw is 115 mA @ 14 VDC plus @1.8 mA/LED

[0157] 5. Sleep Mode: Minimum power draw is 13 mA @ 14 VDC

[0158] 6. LED indication when powered by Primary Power source

[0159] 7. Back-up Battery Input

[0160] 8. Power Requirement 9-30 VDC

[0161] In the Operational Mode, the minimum power draw is 102 mA @ 12VDC plus @ 1.8 mA/LED

[0162] In the Sleep Mode:

[0163] 1. The RTU is configured to enter Sleep mode by software logic.

[0164] 2. The RTU awakens upon:

[0165] 3. Return of power

[0166] 4. Alarm Clock setting

[0167] 5. Modem ring indication

[0168] The preferred overall dimension of the RTU is 6.14 W×11.5 L×1.35H with mounting plate.

[0169] The firmware of the RTU's control, data acquisition, alarm andevent, and data logging capabilities are configured with the RTUMaintenance Environment (ARME). In addition all hardware options areconfigured from ARME. No hardware jumpers, switches or plug-ins arerequired.

[0170] The RTU 4000E supports the Modbus protocol standard, and canmonitor 17 million RTU Addresses, provide:

[0171] 1. Exception Reporting

[0172] 2. Scatter Reads (Registers do not have to be contiguous.)

[0173] 3. Mixed Data Type Messaging, and

[0174] 4. Security/Access privileges configurable per port, which are

[0175] a. Read Only

[0176] b. Read/Write, or

[0177] c. Read/Write/ Configure.

[0178] The master protocols supported by the invention include:

[0179] 1. Modbus ASCII and RTU

[0180] 2. Daniels Modbus ASCII and RTU

[0181] 3. Enron Modbus

[0182] 4. Rosemount 3095 Modbus

[0183] 5. Extended Modbus

[0184] 6. Yokagawa Power Quality Monitor

[0185] Slave protocols supported include:

[0186] 1. Modbus ASCII and RTU,

[0187] 2. Daniels Modbus ASCII and RTU,

[0188] 3. Enron Modbus,

[0189] 4. Extended Modbus.

[0190] For Data Acquisition, on power-up all RTU I/O is accessible viaEIA-232 and Modbus addressing, no programming required. In addition,

[0191] 1. Data archival sampling rates are configurable from seconds tohours.

[0192] 2. RTU flash RAM that is available for data archival can store365 days of hourly data for 24 points. Over 250,000 records availablefor storage.

[0193] The invention allows up to 100 function blocks can be configuredto address control, data acquisition, data logging or alarmapplications. The function blocks can be:

[0194] 1. Accumulator/Totalizer Block

[0195] 2. AGA Block Compressible Fluid

[0196] 3. Incompressible Fluid

[0197] 4. AGA 3

[0198] 5. AGA 8 Detailed

[0199] 6. AGA 8 Gross 1

[0200] 7. AGA 8 Gross 2

[0201] 8. AGA 7

[0202] 9. Alternate Block

[0203] 10. Analog Alarm Block

[0204] 11. Analog Input Block

[0205] 12. Archive Block

[0206] 13. Boolean/Math Block

[0207] 14. Cryout Block

[0208] 15. Digital Alarm Block

[0209] 16. LCD Block

[0210] 17. Mapping Block

[0211] 18. Momentary Block

[0212] 19. On/Off Control Block

[0213] 20. PID Control Block

[0214] 21. Scale Block

[0215] 22. Staging Block

[0216] 23. Sleep Block

[0217] 24. Stop Watch Block

[0218] 25. System Block

[0219] 26. Timer BlockValve Block

[0220] 27. User definable Function Blocks via Soft RTU Toolkit

[0221] The Enterprise Server includes:

[0222] 1. On-line configuration supports non-stop communication withfield devices.

[0223] 2. Communication Server runs as a Service in Windows NT 4.0 and2000.

[0224] 3. Communication support includes,

[0225] 4. Real-time data polling,

[0226] 5. Archival data uploads from field devices, and

[0227] 6. Exception reports or Cryouts from field devices.

[0228] 7. Configuration tools are ActiveX controls that can be run in anOLE

[0229] 8. Container Compliant HMI or Browser. Remote AdministrationSupported.

[0230] 9. Embedded diagnostics logs performance information andforensics data to

[0231] 10. ASI Viewer and/or Log File.

[0232] 11. Most communication functions and controls are accessible toexternal applications through the OPC Server interface.

[0233] 12. Embedded Client triggers,

[0234] 13. Enables real-time data caching for OPC Client applications.

[0235] 14. Automatic archived data uploads from field devices withoutOPC Client application.

[0236] 15. Item aliases supported for protocol independent HMI/ClientApplication development.

[0237] 16. Browsing supports protocol specific data types/items andAliases.

[0238] 17. Multiple protocols can be supported on a single communicationchannel.

[0239] Telemetry methods, which are usable in this invention, include:

[0240] 1. Serial Cable, Leased-line or Serial Multi-drop,

[0241] 2. PSTN and PPP via Modem,

[0242] 3. Radio (Conventional, Trunking, and Spread- Spectrum Radio),

[0243] 4. VSAT,

[0244] 5. TCP/IP Ethernet, TCP/IP Ethernet Terminal Servers, and IP.

[0245] Protocols Modules include:

[0246] 1. Modbus Module

[0247] 2. Modbus RTU and ASCII

[0248] 3. Omni 3000/6000 Modbus (Real-time Data, and History and ReportUploads)

[0249] 4. Daniels Modbus RTU and ASCII (Real-time Data and HistoryUploads)

[0250] 5. Enron Modbus (Real-time Data and History Uploads)

[0251] 6. Flow Automation Modbus (Real-time Data and History Uploads)

[0252] 7. ABB TotalFlow Modbus (Real-time Data and History Uploads)

[0253] 8. Motorola MOSCAD Modbus

[0254] 9. Delta X Modbus (Real-time Data and Dynagraph Cards)

[0255] 10. Baker CAC Modbus (Real-Time Data and Dynagraph Cards)

[0256] 11. User Configurable Register Sets

[0257] a. Bristol Babcock BSAP Module

[0258] b. ABB TotalFlow Packet (Native) Protocol Module (Real-time Dataand History Uploads)

[0259] c. ABB HCI-A Module (AAI Analyzers)

[0260] d. Allen Bradley DF1 Module

[0261] 12. Master-Slave (Half Duplex)

[0262] 13. Point-To-Point (Full Duplex)

[0263] a. Fisher ROC Module (ROC 300 Series, FloBoss 407, 500 Series)(Realtime Data and History Uploads)

[0264] b. GE SNP Module

[0265] c. GE 90 Series PLC Ethernet Module

[0266] d. HP48000 Module (Real-time Data and History Uploads)

[0267] e. Cutler Hammer—IMPACC System Communications Module

[0268] f. Detroit Diesel DDEC Module (Detroit Diesel ElectronicController)

[0269] g. General Motors EMD MDEC Module (Marine Diesel ElectronicController)

[0270] h. Caterpillar ECM Module (Electronic Controller Module)

[0271] i. Nautronix ASK Module

[0272] j. Mercury ECAT, ER Module (Real-time Data and History Uploads)

[0273] k. Teledyne CA, TGP Module

[0274] 14. Preferred Server Interface Formats include:

[0275] a. OPC (OLETM for Process Control)

[0276] b. Microsoft CF_TEXT, XlTable

[0277] c. Rockwell Software AdvanceDDETM

[0278] d. Wonderware FastDDETM

[0279] 15. The types of communication transactions include:

[0280] a. Real-time Data

[0281] b. Interval Polling at 15 different intervals (Periodic TimerTriggered)

[0282] c. Slow Polls at 15 Intervals are a percentage of PollingInterval (Faster and Slower rates are supported.)

[0283] d. Synchronous Polling (Clock or Calendar Triggered)

[0284] e. Demand Polling (DDE/OPC Client Triggered)

[0285] f. History/Archived data Uploads

[0286] g. Interval Uploads at 15 different intervals (Periodic TimerTriggered)

[0287] h. Slow Uploads at 15 Intervals are a percentage of PollingInterval (Faster and Slower rates are supported.)

[0288] i. Synchronous Uploads (Clock or Calendar Triggered)

[0289] The AES can communication without an OPC request from an externalClient. It provides more deterministic performances as real-time dataitems are constantly active. The data collected is cached for deliveredto external Client applications via the Server interface. Providesstandalone history/archived data uploads from field devices for storagein database or audit files without the requirement of an externalClient.

[0290] Documentation and Configuration, the invention permits thefollowing:

[0291] 1. OLE DB interface support for all leading relational databases.

[0292] 2. Database driven external configuration tools to easemaintenance of large applications.

[0293] 3. Database driven reports to document AES configuration.

[0294] 4. Database tools to support simultaneous configuration ofHMI/Client Application and AES.

[0295] 5. SCADA Capabilities, this invention allows:

[0296] a. Client access to communication diagnostics for each telemetrychannel and for each RTU/PLC.

[0297] b. One AES installation to support multiple protocols.

[0298] c. Multiple protocols can be supported over one communicationchannel.

[0299] d. Client-Server interface to give a Client full control of allaspects of the server including:

[0300] (1) Polling Interval

[0301] (2) Demand Polling

[0302] (3) Telephone number for dial-up

[0303] e. AES redundant devices: RTU/PLCs.

[0304] f. Automatic fail-over to back-up device

[0305] g. AES supports redundant telemetry channels/methods to a singledevice:

[0306] h. Data Logging:

[0307] (1) Uploaded data can be logged to any leading database via OLEDB.

[0308] (2) EFM data uploads can be written to Flow Cal files or to FlowCal Enterprise (Oracle) format.

[0309] (3) User defined periodic file closing: file size control

[0310] (4) User defined path to file location

[0311] (5) User defined directory and file labels identify file content,date and time.

[0312] (6) User defined automatic file purging: directory size control

[0313] i. Diagnostic Logging:

[0314] (1) AES logs diagnostic and forensic data to an ASI Viewer and/orLog file.

[0315] (2) Data that can be activated for Diagnostic Logging includesthe following.

[0316] j. Message Errors

[0317] k. Send Messages

[0318] l. Receive Messages

[0319] m. Device and Item Activity

[0320] n. Status Changes

[0321] o. Client Data Received

[0322] p. Field Device Data Received

[0323] q. Event Notification from Ports

[0324] r. Receive Buffer Contents and Data

[0325] s. Item Name, Value and Quality

[0326] t. Changes in Client Status

[0327] u. Changes in AES Configuration

[0328] v. Data Flow Between AES Components

[0329] w. Performance Data regarding Threads

[0330] x. AES Footprint or Tracing Information

[0331] The invention has as features:

[0332] 1. Control, alarm monitoring, data logging, data acquisition, andcommunication functions of the embedded SoftRTU are implemented usingARME.

[0333] 2. Data acquisition immediately on power-up without configuringor programming.

[0334] 3. A fill-in-the-blank configuration interface that is used tosetup RTU functions without programming.

[0335] 4. Ability to reconfigure RTU's while they are on-line.

[0336] 5. Loading of new configurations over the telemetry system.

[0337] 6. Loading of RTU configurations to be uploaded and modifRTU fordownloading to other RTU's.

[0338] 7. Configuration to archive data for periods greater than oneyear to nonvolatile memory.

[0339] 8. Synchronization utilities between the RTU and the hostcomputer.

[0340] This SCADA system can be used for:

[0341] 1. Electrical Power Quality Monitoring

[0342] 2. Electronic Flow Measurement (EFM)

[0343] 3. Compressor Control

[0344] 4. Wastewater Collection and Water Distribution Systems

[0345] 5. Pump Control

[0346] 6. Pipeline Valve Control

[0347] 7. Surveillance

[0348] 8. Environmental Monitoring

[0349] 9. Traffic Control

[0350] 10. Safety and Early Warning Systems

[0351] Connection features are as follows:

[0352] 1. Connection (TAC) is a data logger that has a DDE/OPC ClientInterface.

[0353] 2. TAC can acquire data from any DDE, OPC or ODBC source, andstore the data via ODBC to any compliant database.

[0354] 3. TAC can also retrieve data from the database and write thedata to an RTU or PLC via the DDE/OPC Server.

[0355] 4. Data is acquired on an Interval, External Trigger, Change inValue or Change of State, and synchronous with the clock.

[0356] 5. Multiple logging or retrieval plans, called Schemes, can beconfigured to transfer data periodically or on event for variousbusiness, engineering, or research purposes. Each logging Schemesubsequently writes the data to its specific database file format or toa file.

[0357] 6. TAC also has a Watch-Dog-Timer to insure data is not lostduring a network failure or due to the loss of a network storage device.Data is logged to the secondary path on failure of the Watch-Dog-Timer.

[0358] 7. The intervals at which TAC log files are closed areconfigurable for each Scheme.

[0359] 8. The interval at which the directory for TAC log files ispurged is configurable for each Scheme.

[0360] 9. DDE formats supported include Microsoft formats and AdvancedDDE.

[0361] 10. TAC is especially suited for uploading time-stamped data fromintelligent data acquisition and control systems.

[0362] 11. TAC runs on Windows 95 and Windows NT.

[0363] The above description of preferred embodiments is not intended toimplRTUly limit the scope of protection of the following claims. Thus,for example, except where they are expressly so limited, the followingclaims are not limited to a method wherein the simulation data istransferred to the RTU. The simulation data could be stored locally inmemory, on magnetic disk, magnetic tape or the like. Moreover, theclaims are not limited to a method of entering simulation mode byremoving the register update module from the task list. Other methodscould be equally effective. For example, the register update modulecould itself recognize the RTU mode and withhold from storing data inthe registers.

1. A method for communication for a supervisory control and dataacquisition (SCADA) system, the SCADA system comprising: (a) anenterprise server; (b) at least one intelligent electronic device (RTU),wherein the RTU measures a physical process and stores digital datarepresentative of the measurement in a memory area for transmission; andsaid RTU has software that includes a generic encapsulation layer (GEL)and automation software; (c) a communication software (AES) linking theenterprise server with the at least one RTU.
 2. The method comprisingthe steps of: (a) communicating a command from the enterprise server tosaid RTU via the AES to configure said RTU; (b) permitting said RTU toreceive data input and to store said data; and (c) transmitting saiddata back from the RTU to the AES and the enterprise server.
 3. Themethod of claim 1, wherein the configuration functionality iscommunicated to said RTU without the use of primary signal injectionequipment using the AES
 4. The method of claim 1, wherein said RTUcomprises: (a) an analog-to-digital converter (ADC) for measuring thephysical process and converting the measurements into a digitalrepresentations of the measured values; (b) a memory area for storingdigital representations of the measured value; (c) at least oneprocessor in communication with said ADC and said memory area, saidprocessor operating upon said digital representation of the measuredvalues according to a predetermined function, and said processorselectively moving said digital representation of the measured values tosaid memory area; (d) a command register for storing communicationcommands, said command register being in communication with saidprocessor such that said processor moves said digital representaton ofthe measured values to said memory area when the command registercontains an enabling communication command; (e) at least onebidirectional port in communication with the AES and enterprise serverfor transmitting said digital representation of the measured values tothe enterprise server from the RTU via the AES; and (f) wherein saidbidirectional port receives digital representation of the measuredvalues from the AES such that said processor reconfigures the RTU. 5.The method of claim 1, wherein said RTU comprises: (a) ananalog-to-digital converter (ADC) for measuring the physical process andconverting the measurements into a digital representations of themeasured values; (b) a memory area for storing digital representationsof the measured value; (c) at least one processor in communication withsaid ADC and said memory area, said processor operating upon saiddigital representation of the measured values according to apredetermined function, and said processor selectively moving saiddigital representation of the measured values to said memory area; (d) acommand register for storing communication commands, said commandregister being in communication with said processor such that saidprocessor moves said digital representation of the measured values tosaid memory area when the command register contains an enablingcommunication command; (e) an input port in communication with the AESand enterprise server for transmitting said digital representation ofthe measured values from the enterprise server to the RTU via the AESand wherein said processor reconfigures the RTU.; (f) an output port incommunication with the AES and enterpriese server for transmittingdigital representation of the measured values from the RTU via the AESto the enterprise server.
 6. The method of claim 4, wherein saidautomation software of said RTU can perform at least one of theactivities: meter utilities, detect abnomal operating conditions,perform data processing, control operating conditions and combinationsthereof.
 7. The method of claim 5, wherein said automation software ofsaid RTU can perform at least one of the activities: meter utilities,detect abnormal operating conditions, perform data processing andcontrol operating conditions.
 8. The method of 1, wherein said RTUcontinues to operate said automation software while receivingcommunication commands and executing reconfiguration commands.
 9. Themethod of claim 1, wherein said AES continues communicating withconnected RTUs while an additional enterprise server is added to theSCADA system.
 10. The method of claim 1, wherein said AES continuescommunicating with connected RTUs while an additional enterprise serveris removed from the SCADA system.
 11. The method of claim 1, whereinsaid AES continues communicating with connected RTUs while an additionalRTU is added to the system.
 12. The method of claim 1, wherein said AEScontinues communicating with connected RTU's when an RTU is deleted fromthe system.
 13. The method of claim 4, wherein said bidirectional portis in electrical communication with the AES.
 14. The method of claim 4,wherein said bidirectional port is in wireless communication with theAES.
 15. The method of claim 5, wherein said input port, output port, orcombination thereof is in electrical communication with the AES.
 16. Themethod of claim 5, wherein said input port, output port, or combinationthereof is in wireless communication with the AES.
 17. The method ofclaim 1, wherein said RTU is configured with configuration software(ARME).
 18. The method of claim 1, wherein said AES utilizes separateconfiguration software.